General Information table of contents

Before Servicing 1_2

Model Identification 1_8

General Specifications 1_10

Technical Information - Air Inlet System -|_15

Technical Information - New Ignition Interlock Sidestand 1-19

Technical Information - Tail/Brake Lights Employing LED 1-20

Technical Information - KAWASAKI LOW EXHAUST EMISSION SYSTEM 1-22

Unit Conversion Table 1_23

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Before Servicing

Before starting to perform an inspection service or carry out a disassembly and reassembly opera- tion on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustra- tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary. This section explains the items that require particular attention during the removal and reinstallation or disassembly and reassembly of general parts.

Especially note the following:

Battery Ground

Before completing any service on the motorcycle, discon- nect the battery wires from the battery to prevent the engine from accidentally turning over. Disconnect the ground wire (-) first and then the positive (+). When completed with the service, first connect the positive (+) wire to the positive (+) terminal of the battery then the negative (-) wire to the neg- ative terminal.

Edges of Parts

Lift large or heavy parts wearing gloves to prevent injury from possible sharp edges on the parts.

Solvent

Use a high flush point solvent when cleaning parts. High flush point solvent should be used according to directions of the solvent manufacturer.

Cleaning vehicle before disassembly Clean the vehicle thoroughly before disassembly. Dirt or other foreign materials entering into sealed areas during ve­hicle disassembly can cause excessive wear and decrease performance of the vehicle.

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GENERAL INFORMATION 1-3

Arrangement and Cleaning of Removed Parts Disassembled parts are easy to confuse. Arrange the parts according to the order the parts were disassembled and clean the parts in order prior to assembly.

Storage of Removed Parts After all the parts including subassembly parts have been cleaned, store the parts in a clean area. Put a clean cloth or plastic sheet over the parts to protect from any foreign materials that may collect before re-assembly.

Inspection

Reuse of worn or damaged parts may lead to serious ac- cident. Visually inspect removed parts for corrosion, discol- oration, or other damage. Refer to the appropriate sections of this manual for service limits on individual parts. Replace the parts if any damage has been found or if the part is be- yond its service limit.

Replacement Parts

Replacement Parts must be KAWASAKI genuine or rec- ommended by KAWASAKI. Gaskets, O rings, Oil seals, Grease seals, circlips or cotter pins must be replaced with new ones whenever disassembled.

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Before Servicing

Assembly Order

In most cases assembly order is the reverse of disassem- bly, however, if assembly order is provided in this Service Manual, follow the procedures given.

Tightening Sequence

Bolts, nuts, or screws must be tightened according to the specified sequence to prevent case warpage or deformation which can lead to malfunction. If the specified tightening sequence is not indicated, tighten the fasteners alternating diagonally.

Tightening Torque

Incorrect torque applied to a bolt, nut, or screw may lead to serious damage. Tighten fasteners to the specified torque using a good quality torque wrench.

Force

Use common sense during disassembly and assembly, excessive force can cause expensive or hard to repair dam- age. When necessary, remove screws that have a non -permanent locking agent applied using an impact driver. Use a plastic-faced mallet whenever tapping is necessary.

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GENERAL INFORMATION 1-5

Gasket, Oring

Hardening, shrinkage, or damage of both gaskets and O-rings after disassembly can reduce sealing per- formance. Remove old gaskets and clean the sealing surfaces thoroughly so that no gasket material or other material remains. Install new gaskets and replace used O-rings when re-assembling

Liquid Gasket, Locking Agent For applications that require Liquid Gasket or a Locking agent, clean the surfaces so that no oil residue remains be- fore applying liquid gasket or locking agent. Do not apply them excessively. Excessive application can clog oil pas- sages and cause serious damage.

G8020166 S

Press

For items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the contact area. Be sure to maintain proper alignment and use smooth movements when installing.

Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is absolutely necessary. Replace with new ones whenever removed. Press bearings with the manufacturer and size marks facing out. Press the bearing into place by putting pressure on the correct bearing race as shown.

Pressing the incorrect race can cause pressure between the inner and outer race and result in bearing damage.

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